Machine for applying a protective lip



March 16, 1965 c. z. MONROE 3,173,824

r MACHINE FOR APPLYING A PROTECTIVE LIP Filed May 3, 1961 4 Sheets-Sheet l "I, ii

JNVENTOR.

611421.55 Z NON/20E BY wmm A'TrokA/EV5 March 16, 1965 c. z. MONROE MACHINE FOR APPLYING A PROTECTIVE LIP 4 Sheets-Sheet 2 Filed May 3. 1961 INVENTOR. CHHRLES Z. MONROE 4TTORNEY$ March 16, 1965 c. z. MONROE MACHINE FOR APPLYING A PROTECTIVE LIP 4 Sheets-Sheet 3 Filed May 3, 1961 INVENTOR. C/MRL 5 Z. Mala/Ros F/G. ll

March 16, 1965 c. z. MONROE 3,173,824

MACHINE; FQR APPLYING A PROTECTIVE LIP Filed May 3, 1961 4 Sheets-Sheet 4 FIG. /2 P C'HHELES Z MONROE wwmm;

ATTORNE V5 United States Patent ()fiiice $173,824 Patented Mar. 16,1965

3,173,824 MACHINE FOR AIPLYING A PROTECTIVE LIP Charles Z. Monroe, Detroit, Mich, assignor to Ex-Cell-O Corporation, Detroit, Mich, a corporation of Michigan Filed May 3, 1961, Ser. No. 107,452 1 Claim. (Cl. 156-484) This invention relates to packaging machines in general and more particularly to a machine for providing a protective lip on packaging containers and the like. As hereinafter described, this invention is more specifically directed to apparatus for providing a protective lip on the pouring spout of fluid dispensing carton members.

Plastic coated carton members are being used in increasing quantities as fluid retaining containers in place of glass bottles. The most prevalent use of such containers is in the dairy field for milk and like products where sanitary conditions are of the utmost importance.

Milk and like fluid retaining cartons are usually made of virgin wood pulp and have a polyethylene coating provided on both sides thereof. However, because of mass production requirements, the edges of the cartons are usually uncoated. This is no particular problem in most instances because the carton edges are not exposed. The only exception is as regards the spout over which the retained fluid is poured from the container.

The pouring spout of most fluid retaining cartons is provided by folding out certain top forming parts of the carton. Accordingly, the exposed edge of the carton is susceptible to fluid saturation and gradual minimization of its pouring efficiency. This occurs only in those instances where small quantities of fluid are poured from a container at a time but it is nevertheless a problem which requires a solution in providing a high-quality product.

It is of further significance, in discussing the pouring spout of the more common type of fluid retaining containers, that the edges of the pouring spout are normally required to be sealed within the top closure of the container and still be withdrawn therefrom without damage.

Those containers which include a wax or polyethylene coating on the carton walls are normally sealed about thepouring spout by thermal means coacting with the coating on the sealing flaps. This provides a good fluid tight seal and still enables the pouring spout to be readily withdrawn for use. However, the side edges of the pouring spout which are engaged together and are dis posed next adjacent the carton sealing flaps become too frequently sealed together and are later damaged when the spout is extracted.

The disposable nature of the fluid retaining cartons under discussion necessitates minimal material costs and a high rate of production which has not been achieved by previous efiorts to solve the problems mentioned.

The principal object of this invention is to provide a machine for automatically applying a suitably protective covering over the edge of a receptive member, such as the pouring spout of a fluid dispensing carton, at a high rate of production.

It is also an object of this invention to teach the method and a suitable means of applying a protective edge covering or lip to a receptive member without interrupting the normal course or rate of travel.

Another object of this invention is to disclose an in provement in fluid dispensing cartons which includes providing a particular form of protective covering over the edge of the pouring spout thereof and such as may be readily applied by automated equipment, can be sealed within the closed carton and may be subsequently withdrawn for use without damage.

More specifically:

It is an object of this invention to provide a machine device which will automatically process a plurality of carton forming blanks through a mechanism which will feed a protective lip forming member across the path of travel of such cartons as they pass thereby and will cut off such lip forming member, synchronously with the rate of travel of the carton members, in a manner whereby they will be picked up by the cartons in their course of travel and will be subsequently afiixed thereto without interruption or delay.

These and other objects and advantages to be gained in the practice of this invention will be further under stood and appreciated upon a reading or" the following specification having particular reference to the embodiment shown by the accompanying drawings.

In the drawings:

FIGURE 1 is a side view of a machine embodying the teachings of the subject invention. Certain parts of the machine are cut away to better illustrate important features thereof.

FIGURE 2 is an open plan view of a carton blank showing a protective lip provided thereon.

FIGURE 3 is an end view of the top section of a carton formed by the carton blank shown by FIGURE 1.

FIGURE 4 is a side View of the carton member formed by the carton blank of FIGURE 1 showing the pouring spout as disposed for use.

FIGURE 5 is an enlarged side view of a part of the machine shown by FIGURE 1 wherein the carton blanks are advanced into the feeder head mechanism.

FIGURE 6 is an enlarged side view of the apparatus which provides the protective lip on the carton blank members received therethrough.

FIGURE 7 is an end view of the lip-feeding apparatus shown by FIGURE 6.

FIGURE 8 is an enlarged cross-sectional plan view of the feeder head sub-assembly as seen in the plane of line 83 of FIGURE 6, looking in the direction of the arrows thereon.

FIGURE 9 is a cross-sectional view of the feeder head showing the gear train arrangement provided therein. This View is taken in the plane of line 9-9 of FIGURE 8, looking in the direction of the arrows thereon.

FIGURE 10 is a cross-sectional view of the feeder head mechanism as seen in the plane of line 1016 of FIGURE 8.

FIGURE 11 is an enlarged top plan view of the guide plate arrangement shown by FIGURE 6 and as seen in the plane of line IIII, looking in the direction of the arrows thereon.

FIGURE 12 is an enlarged cross-sectional view of a fragmentary section of the machine shown by FIGURE 1 taken in the plane of line l2]l2 thereon.

FIGURE 13 is an enlarged cross-sectional View of the knife roller.

FIGURE 14 is a diagrammatic illustration of the protective lip feeding apparatus disclosed by the other figures of the drawings.

FIGURE 15 is a lip covers.

FIGURE 16 is an edge view of one or" the protective lips showing the shape to which it is first folded.

FIGURE 17 is a perspective view of one of the protective lips showing the general shape to which the member is folded when provided on a carton member.

Referring to the drawings in further detail:

The machine 10, shown by FIGURE 1, includes an open chamber area 12 wherein a stack of carton blanks plan view of one of the protective 'on' the side thereof.

. the lip feeder mechanism 22. They pass from the lip feeder mechanism 22 to a series of rotating heat sealers As will subsequently be appreciated, the carton feeding mechanism 16, carton conveying systems 18 and 20, lip

feeder mechanism 22 and the rotating heat sealers 24 are all synchronously operated. A drive motor 26 and a suitable drive chain arrangement 28 affords the necessary drive power and suitable'machine controls 30 are conveniently provided for operation of the disclosed apparatus.

The carton blanks 14, in the present instance, are such as is shown by FIGURE 2. These are fluid retaining container blanks, such as are used for milk and other dairy products. They are made of a virgin wood pulp and include a polyethylene coating provided on both sides thereof for sealing against fluid absorption. As previously mentioned, the edges of the carton blanks are not coatedyprincipally because of the mass production requirements which make it easier to form the carton blanks-in large sheets which are later cut to the specific size of the carton blank itself.

Each carton blank 14 is suitably scored to provide the side Walls 32 and the interconnecting end flap 34. The top'forming sections 36 of the side walls are suitably scored for folding as at 38 and 40 to enable folding the top section 36 and suitably closing the top of the container which is formed.

The scoring 38 provided on the top forming sections 36 is also such as will provide a pouring spout 42, (reference FIGURE 4). It is on the edge of this pouring spout 42 that the protective lip 44 is provided.

The fluid retaining carton, as finally formed, is closed at thetop' thereof by havingthe top forming sections 36 folded in and the sealing flaps 46 thereon engaged together. 'This is best shown by FIGURE 3 wherein only the terminal edges of the sealing flaps 46 are shown as secured together and the sealing area next adjacent thereto is shown spaced apart to emphasize the sealing area within which't-he protective lip 44 is disposed.

The protective lip 44 is made of a non-thermal-responsive'material, such as cellophane,which preferably, but not necessarily, has a thermal-responsive coating provided While it will not adhere to itself upon'the application of heat, it may be bonded to the polyethylene coated walls of the carton member. The

sealing'is of course enhanced whenthe flap engaging side of the lip member is coated as mentioned. Accordmgly, while the flaps 46 may be sealed together due to their thermal-responsive polyethylene coating, the area of the flap '46 which forms the pouring spout and is covered by the protective lip 44 will be sealed within the V protection of the overlapping flaps but will not itself be sealed together and therefore will not be damaged when the flaps are opened to provide the pouring spout 42.

w The advantages which are provided by the use of the p rotective lip 44 are'readily apparent. The uncoated edgeof the carton blank 14 which is used to form the pouring spout 42 is sealedagainst fluid absorption which would otherwise minimize the pouring effectiveness thereof. Further, the protective lip 44 is'so formed and disposed as to enable the flaps 46 which close the container to be adequately secured together'and still enable the pouring spout to be subsequently removed without damage.

Referring now to the means and methods disclosed for providing the protective lip 44 on a carton blank 14:

The carton blanks are received from the carton feeding mechanism 16 on to horizontally disposed guide rails 48 which extend past the lip feeder mechanism 22 and a pair of spaced sprocket wheels 54 andf56 which operate a sprocket chain 58 having suitable'lugs 60 provided thereon which engage the trailing-end of the carton blanks and move'them forward. The driving lugs 60 are spaced apart a distance sufficient to enable feeding the protective lip forming material between carton blanks 14, as will subsequently be described, and to progress the blanks 14 in aligned and spaced relation towards the lip feeder mechanism 22. 7

Referring now to FIGURES 6 through 10:

The lip feeder mechanism 22 includes a tape roll 62 of'cellophane material in strip form which is usedto' form the protective lip covering 44. The tape roll '62 is rotatably supported by parallel spaced vertical supports 64 engaged to a crossbar or bridge 66 between the sides of the machine 10 through a support bracket 68. A suitable friction drag (not shown) prevents any overrun of the tape roll.

A feeder head 70 is supported on the end of the tape roll supporting fixture. Suitable basically tension rollers 72 and 74 guide the protective tape material to the feeder head 70. An overcenter spring loaded roller 76 holds the protective material against the feedroller 78.

Carton receptive guide plates 80 and 82 are disposed in parallel spaced relation under the feeder head 70. The upper plate 80 is secured to the feeder head and the lower plate is secured to a vacuum manifold 84.

The vacuum manifold 84 is supported by vertical members 86 and 88 extending upward from a cross bridge 90 which extends between the sides of the machine 10. Suitable suction tubing 92 is connected tothe vacuum manifold 84 and has the terminal end thereof emptying in a collection bag 94, shown by FIGURE 1.

The Vacuum manifold 84 is disposed and arranged relative to the feeder head 70 to orient and stabilize the terminal end of the lip providing material in the path of the carton blank members. Further, in the event that a carton blank is not disposed to receive the protective lip forming member when it is cut from the tape roll, the vacuum manifold 84 and connecting suction tubing 92 will remove the mis-fired member and carry it to the collection bag 94.

The feeder head 70 includes a housing 96 having the feed roller 78 mounted therein. The feed roller 78 is journaled within the housing side walls 100 and is driven through the roller supporting'shaft 102 extending through one of the side walls.

The feed roller 78 is exposed through one side of the housing 96 and is engaged by the overcenter spring loaded guide roller 76; As will be appreciated, the protective lip forming strip is thereby held against the knurled surface 104 of the feed' roller. It will also be noted that the feed roller 78 includes a plurality of circumferentially spaced knife blades 106 centrally thereof for slitting the protective tape at spaced intervals and longitudinally thereof as it passes over the feed roller.

A suitable drive gear 108 is provided on the feed roller shaft 102 and engages and drives a series of gear members110, 112 and 114 which are respectively operative of a back-up and coordinating roller 116, a knife roller 118 and an anvil roller 120. This gear drive arrangement is best shown by FIGURE 9 and the different 'rollers mentioned are best shown by FIGURE 10.

The back-up roller 116 is shown as disposed for engagement by the knife roller 118. A cam-follower arrangement (not shown) may also be provided near the ends of the back-up roller shaft 122 for cooperation with the ends of the knife roller shaft 124 where desirable.

The knife roller 118 is shown in enlarged cross-section by FIGURE 13. It includes a plurality of axially disposed and circumferentially spaced cutting edges 126 which project beyond the periphery of the knife roller itself. The knife roller 118 preferably has a slower surface feed than the feed roller '78, to preclude any feeding thereby, and the extension of the knife blade cutting edges 126 beyond the periphery of the roller itself picks up this slack and affords a slight tensioning of the tape material and a cleaner and easier cutting thereof as the anvil roll bottoms against its stop.

It will be appreciated that a different type of knife roller 118, such as one having removable knife blades, may be used and so provided as to incorporate the tensioning feature last mentioned.

The anvil roller 126 is supported within an anvil shoe 128 which is held in tensioned engagement with the knife roller 118 relative to a back-up member 130.

The guide plates 8t} and 82 through which the carton blanks 14 travel are best shown by FIGURE 11. The upper plate member Bil as mentioned, is secured to the bottom of the feeder head '70 and includes suitably relieved areas 132 within which the drive gears, knife roller and anvil roller may be received. It is also formed to include a protective tape receptive passageway 134 having a straight back edge 136 and a contoured leading edge 138; that is, relative to the passage of a carton blank thereunder. The upper plate 8! also includes parallel spaced spring fingers 140 which extend beyond the terminal end thereof and over the lower plate 82.

The lower guide plate 82 is sufficiently longer than the upper guide plate St) to accommodate the spring fingers 140. However, the extended part of the lower plate is cut away as at 142 to provide an open space between the spring finger members. It is formed to include a tape receptive passageway 144 which is relatively aligned with the similar passageway 134 through the upper guide plate. The passageway 144 through the lower guide plate is preferably contoured to the shape of the carton blank sealing flap 45' at both the trailing edge 146 and the leading edge thereof. The contours of the trailing edge 146 precludes any vacuum manifold effect on the carton lip 46' as it travels over the passageway. The contour of the leading edge will be later explained in further detail.

Referring now to FIGURES 14 through 17:

FIGURE 14 diagrammatically illustrates the synchronized feeding of carton blanks 14 through the feeder head 70 in timed relation to the feeding of the protective lip forming tape material through the feeder mechanism 22. As the carton blanks 14 are advanced towards the feeder head 76, the protective tape material is being fed by the feed roller 78 through the receptive passageways 134 and 144 of the carton receptive guide plates 80 and 82. The terminal end of the lip forming tape material is threaded through the guide plate passageways between the terminal end of one carton blank and the leading edge of the next succeeding carton blank. The protective lip forming portion is oriented by the air suction through the vacuum manifold 84.

At substantially the instant that the leading edge of the next succeeding carton blank 1 -3 engages the protective lip forming member in its path of travel, the knife roller 118 cuts loose the protective lip 44. The carton blank immediately folds the protective lip member 44 longitudinally to the shape shown by FIGURE 16 and thereafter carries the lip member between the guide plates 89 and $2 where it is wiped into engagement with the pouring spout forming sealing flap 46'. The general shape of the protective lip member 44, as provided on the pouring spout sealing flap 46', is shown by FIG- URE 17.

Followin the cutting of one protective lip member 44 from the terminal end of the tape roll 62, the succeeding terminal end is fed towards the receptive passageways in the guide plates 8%} and 82 while the last lip receiving ill carton blank is passing therethrough. As the terminal end of the preceding carton blank clears the guide plate passageways, the succeeding terminal end of the protective lip forming tape passes through the guide plate passageways and into position for the next succeeding carton blank. The dotted line 147 in FIGURE 14 illustrates the relative advancement of the terminal end of thelip forming tape between the trailing and leading edges of successive carton blank members. In practice, about one-third of the length of the protective lip member 44 is disposed on one side of the carton blank and the other two-thirds thereof is disposed for engagement with the other side thereof.

The longitudinal slit that was provided in the protective material by the knife blades 196, as it passed over the feed roller 78, is shown by FIGURE 15 and identified 149. It is to be so disposed as to intersect the upper out edge of the protective lip member 44. This enables the longer portion of the lip member to be more readily folded to the shape and contour of the receptive carton fl-ap.

Referring to FIGURES l1 and 12, it will be appreciated that it is essentially only the sealing flap 46 which is to receive the protective lip 44 that travels through the guide plates 8th and 82. Further, the spring fingers of the upper guide plate 80 are spaced sufiiciently close together to engage the outer edges of the protective lip member 44 as the carton flap it passes between the spring fingers and over the extension of the lower guide plate member. Thus, the protective lip member 44 is held in engagement with the carton blank 14- and at the same time has its upper and lower sides exposed between the spring fingers and within the cut away section of the lower guide plate.

It is within this accessible area between the spring fingers and within the cut away section of the lower guide plate 82 that sealing engagement is first made with the protective lip member 44 by the heat sealing means 24.

As shown by FIGURES 1 and 12, the heat sealing means 24- includes a plurality of successively disposed heat transmitting members 159 provided on parallel rorating shafts 152 between which the carton blanks 14 are required to travel. The heat transmitting members 15s are so arranged and coordinated on their supporting shafts 152 as will bring the heating elements 154 thereof into engagement with respectively opposite sides of the protective lip member 44 on the carton sealing flap 46'. This is best shown by FIGURE 12 wherein the heating element 154 of the first sealing member is of a size to be received within the cut away section 142 of the lower guide plate 32. It will be appreciated that successive eating elements 154 will be of a size complementary of the width of the protective lip member.

FIGURE 12 shows the gear drive arrangement 156 for coordinating operation of the heating elements on their respective shafts. Although not shown, it will be appreciated that a like gear arrangement is used to coordinate the other heat sealing members on the successively disposed shafts. A suitable gear housing cover 158 is secured to the side 16% of the machine 10 through which the shafts extend.

A suitable slip ring arrangement 162 is disposed for engagement with the other ends of the supporting shafts 152 which extend through the other side 164 of the ma chine. This includes a fixture 166 having a protective conduit 168 through which lea-d wires from a power sup ply source are extended. The power leads are connected to the carbon brushes 170 disposed for engagement with slip rings 172 on the ends of the shafts 152 which support the heat sealing members 150. Lead wires 174 are provided through the supporting shafts 152 for connecting the slip rings to the heater elements 154.

The operation of the disclosed machine 10 is as follows:

A stack of carton blanks 14 are received within the carton stacking chamber area 12 at one end of the mafriction belt ar rangemen-t 18, takes carton blanks 14from the bottom of the stack and the chain drive arrangement receives individual blanks and carries them towards the feeder head 70 of the lip feeding mechanism 22 in aligned and spaced relation.

"50 and are supported on the guide rails 48 in such a man- 'ner as assures that the "carton flap 46 which is intended to form the container pouring spout will pass through the feeder head 70. 1

The feed roller 78, as previously mentioned, feeds the protective lip forming material from the tape roll 62 transversely across the path of the carton blanks 14 via 80 and 82 through which the carton blanks are required to pass.

The knife roller 118 within the feeder head 76 is coordinated with the tape feeding roller 98 and in turn with the carbon blank conveyor means 29 to cut off the terminal end of the tape material substantially at the inst-ant that the leading edge of a carton member engages the terminal end of the tape material extending through the guide plates.

As the carton blank continues its travel, the protective lip 44 is picked up and carried through the guide plates 80 and 82 and, in the course thereof, is folded over the leading edge of the carton blank and against the sides thereof.

As the leading edge of the carton blank which now has the protective lip 44 engaged therewith, is exposed between thespring fingers 140 of the upper guide plate and within the cut away section 142 of the lower guide plate, the first set of heating elements 154 is engaged therewith. This causes the thermal responsive polyethylene material with which the carton blank is coated to hold the protective lip member 44 thereto. The successively disposed heat sealing means 24, in the course of their engagement with the protective lip member, complete the heat sealing operation of the protective lip member to the pouring spout flap of the carton blank.

Subsequently, the carton blank 14 will be processed through a carton forming machine (not shown) wherein the carton will be formed, the carton bottom provided, and the top forming sections 36 of the blank left open so that the carton may be filled. Subsequently to the filling of the carton, other apparatus (not shown) will close the top forming sections 36 of the carton blank. This 'is conventionally done by heat sealing means which makes use of the thermal setting character of the polyethylene coating of the carton blanks.

As previously mentioned, the carton will be securely sealed with the pouring spout protective lip 44 folded within the sealed container. However, since the protective lip 44 does not seal against itself, it enables that side of the container which. includes the pouring spout to be more easily opened and assures against damage to the pouring spout itself.

Although a preferred embodiment of this invention has been shown and described in detail, it will be appreciated that certain modifications and improvements are Within the scope and teaching of this invention. Accordingly, such modifications and improvements as are not specifically excluded by the language of the hereinafter appended claim are to be considered as inclusive thereunder.

I claim: 7

A device for providing a protective lip on a receptive member, and comprising: a source :of protective material provided in continuous strip form, strip feeding means receptive of said strip material and operatively disposed relative to said source, means for receiving continuously moving lip receptive members therethrough and for receiving and positioning said strip material adjacent the leading edges of each of said receptive members in the course of travel therethrough, rotating means for cutting a predetermined length of said protective material from said continuous strip synchronously with the feeding of said lip receptive members through said receiving means and operatively substantially upon engagement of said receptive members with said material, said means for receiving said lip receptive members and said strip material being formed to include an opening for the passage of said strip material therethrough transversely of the direction of travel of said lip receptive members, the leading edge of said opening being contoured to the shape of the leading edge of said lip receptive members for the complementary folding of said strip material in the course of engagement by and travel with said receptive member and means for pre-slitting said strip material longitudinally thereof synchronously timed with said cutting means for ultimate edge intersecting exposure of said slit as regards the subsequently cut strip length to facilitating the complementary folding thereof aforementioned.

References Cited by the Examiner UNITED STATES PATENTS 2,050,457 8/56 Ohlsen et a1. 156484 2,787,941 4/57 Aldrich 156522 X 2,864,285 12/58 Roselins 156522 X 2,969,105 1/61 Jones 156-2l6 2,990,081 6/61 De Neui et al 156521 3,011,936 12/61 Baumbach 156506 X EARL M. BERGERT, Primary Examiner.

DOUGLAS J. DRUMMOND, Examiner.

UNITED STATES PATENT OFFICE CE EMCATE OF CORRECTION Patent No 3 ,173, 824 March 16, 1965 Charles Z. Monroe It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 7, line 14, after "via" insert the receptive passageways 134 and 144 in the guide plates Signedand sealed this 17th day ofvAu gustl965.

SEAL) Quest:

ERNEST W. SWIDER' I EDWARD J. BRENNER \ttesting Officer Commissioner of Patents 

